Protective Helmets, Protective Helmet Components and Methods for Manufacturing Protective Helmets, Including Protective Helmets Having an Enlargeable Bell Opening

ABSTRACT

The present invention relates to protective helmets. Embodiments of the invention have been primarily developed to provide protective helmets, protective helmet components and methods for manufacturing protective helmets, including protective helmets having an enlargeable bell opening. For example, embodiments are described by reference to two-part helmets having a hinged connection which permits bell opening enlargement to enable insertion or removal of a human head. One embodiment provides a manufacturing method whereby a protective helmet is formed as a single piece, and then cut into shell portions to which interlocking edge members is subsequently applied, thereby to facilitate reconnection of the shells along an interlocking edge.

FIELD OF THE INVENTION

The present invention relates to protective helmets. Embodiments of theinvention have been primarily developed to provide protective helmets,protective helmet components and methods for manufacturing protectivehelmets, including protective helmets having an enlargeable bellopening. For example, embodiments are described by reference to two-parthelmets having a hinged connection which permits bell openingenlargement to enable insertion or removal of a human head.

BACKGROUND

Any discussion of the prior art throughout the specification should inno way be considered as an admission that such prior art is widely knownor forms part of common general knowledge in the field.

PCT Publication WO 2012/058712 and WO 2007/059575 both disclose examplesof protective helmets having enlargeable bell openings. Morespecifically, those publications focus on hinged rear-opening protectivehelmets, where a front and rear shell rotate relative to one another toprovide an open configuration in which the helmet is able to be appliedor removed, and a closed configuration in which it is secured on awearer's head. This the act of opening enlarges the bell opening of thehelmet, enabling convenient insertion of the head. In some embodimentsthe bell opening is sized thereby to prevent removal of the helmet whenin the closed configuration (referred to as a restricted bell openinghelmet). Other forms of enlargeable (and/or restricted) bell openinghelmets are also possible, for example where two shells are connected byan arrangement other than a dorsal hinge.

There are various technical challenges associated with constructinghelmets having enlargeable bell openings. For example:

Technical challenges arise during manufacture of two-part helmets,particularly where there is a desire to use composite shell materials(as opposed to injection moulding and the like). In particular, it isdifficult to precisely size-match separately formed front and rearshells.There are inherent challenges involved in designing a locking mechanismfor forms of enlargeable (and/or restricted) bell opening helmets, andother forms of helmets having multiple shell portions. In particular,the strength of a locking mechanism should be considerable, for instanceas is necessary to satisfy various helmet safety standardsinternationally.There are inherent challenges involved in designing a hinge mechanismfor forms of enlargeable (and/or restricted) bell opening helmets, andother forms of helmets having multiple shell portions. This is mostprevalent where the helmet is being used for protective purposes, andthere is a need to manage risks associated with a hinge presenting apotential point of failure.

It is an object of the present invention to overcome or ameliorate atleast one of the disadvantages of the prior art, or to provide a usefulalternative.

SUMMARY

One embodiment provides a method of manufacturing a helmet, the methodincluding:

forming a primary helmet shell, the helmet shell having a bell openingdefined by a bell opening edge;

applying a cutting process to the primary helmet shell thereby to definea first shell component and a second shell component, such each of thefirst and second shell components include respective regions of the bellopening edge;

for at least one of the first and second shell components, mounting atleast one interlocking edge member to an edge of the shell component,being an edge defined by the cutting process; and

constructing a helmet including the at least one of the first and secondshell components to which the at least one interlocking edge member ismounted, wherein the constructed helmet is movable between: (i) a closedconfiguration in which the at least one interlocking edge member isengaged with a complementary opposing interlocking edge; and (ii) anopen configuration.

One embodiment provides a method of manufacturing a helmet, including:

for each of the for at least one of the first and second shellcomponents, mounting at least one interlocking edge member to an edge ofthe shell component, being an edge defined by the cutting process; and

constructing a helmet including the first and second shell components,wherein the constructed helmet is movable between: (i) a closedconfiguration in which the respective at least one interlocking edgemembers of the first and second shell components are complementarilyengaged; and (ii) an open configuration.

One embodiment provides a method of manufacturing a helmet, including:

for each of the for at least one of the first and second shellcomponents, mounting a pair of interlocking edge member to an edge ofthe shell component, being an edge defined by the cutting process; and

constructing a helmet including the first and second shell components,wherein the constructed helmet is movable between: (i) a closedconfiguration in which the pair of interlocking edge members of thefirst shell component are complementarily engaged with the pair ofinterlocking edge members of the second shell component; and (ii) anopen configuration.

One embodiment provides a method of manufacturing a helmet, the methodincluding:

forming a primary helmet shell, the helmet shell having a bell openingdefined by a bell opening edge;

applying a cutting process to the primary helmet shell thereby to definea first shell component and a second shell component;

for at least one of the first and second shell components, mounting atleast one interlocking edge member to an edge of the shell component,being an edge defined by the cutting process; and

constructing a helmet including the at least one of the first and secondshell components to which the at least one interlocking edge member ismounted.

Embodiments also include helmets formed by any method described herein.

One embodiment provides a latch assembly for an expandable bell openinghelmet, the latch assembly including:

a first set of latch assembly components which are configured to bemounted to a first shell component of the expandable bell openinghelmet; and

a second set of latch assembly components which are configured to bemounted to a second shell component of the expandable bell openinghelmet;

wherein:

the first shell is movable with respect to the second shell thereby todefine an open and closed configuration for the helmet, wherein: in theopen configuration the bell opening is expanded; and in the closedconfiguration the first set of latch assembly components interface withthe second set of latch assembly components thereby to lock the helmetin the closed configuration; and

the first set of latch assembly components includes: (i) a trappablemember receiving region, wherein the trappable member receiving regionincludes tapered edges configured to guide a trappable member into thetrappable member receiving region; and (ii) a biased capture mechanism,wherein the biased capture mechanism is configured to prevent removal ofthe trappable member in the trappable member receiving region underinfluence of spring loading;

the second set of latch assembly components includes a first platemember that provides the trappable member.

One embodiment provides a latch assembly for an expandable bell openinghelmet, wherein:

the first set of latch assembly components includes a first non-lockingcapture mechanism, wherein the first non-locking capture mechanism isconfigured to be mounted to the first helmet shell component at alocation spaced apart from locking latch assembly components;

the second set of latch assembly components includes a secondnon-locking capture mechanism; which is configured to engage with thefirst non-locking capture mechanism, wherein the second non-lockingcapture mechanism is configured to be mounted to the first helmet shellcomponent at a location spaced apart from locking latch assemblycomponents;

in use, the first and second non-locking latch assembly componentsengage upon closure of the helmet thereby to restrict relative movementof the helmet shell components along at least a first axis and a secondaxis, the first axis being substantially parallel to a shell edge andthe second axis being substantially normal to a shell surface.

One embodiment provides a latch assembly for an expandable bell openinghelmet, the latch assembly including:

a first set of latch assembly components which are configured to bemounted to a first shell component of the expandable bell openinghelmet; and

a second set of latch assembly components which are configured to bemounted to a second shell component of the expandable bell openinghelmet;

wherein:

the first shell is movable with respect to the second shell thereby todefine an open and closed configuration for the helmet, wherein: in theopen configuration the bell opening is expanded; and in the closedconfiguration the first set of latch assembly components interface withthe second set of latch assembly components thereby to lock the helmetin the closed configuration; and

the first set of latch assembly components includes first lockablecomponents;

the second set of latch assembly components includes second lockablecomponents configured to lock to the first lockable components uponclosure of the helmet;

the first set of latch assembly components includes a first non-lockingcapture mechanism, wherein the first non-locking capture mechanism isconfigured to be mounted to the first helmet shell component at alocation spaced apart from the first lockable components;

the second set of latch assembly components includes a secondnon-locking capture mechanism; which is configured to engage with thefirst non-locking capture mechanism, wherein the second non-lockingcapture mechanism is configured to be mounted to the first helmet shellcomponent at a location spaced apart from the second locking components;

in use, the first and second non-locking latch assembly componentsengage upon closure of the helmet thereby to restrict relative movementof the helmet shell components along at least a first axis and a secondaxis, the first axis being substantially parallel to a shell edge andthe second axis being substantially normal to a shell surface.

Embodiments also include helmets including latch assemblies as describedherein.

One embodiment provides a hinge assembly for an expandable bell openinghelmet, the hinge assembly including:

a first set of hinge assembly components which are configured to bemounted to a first shell component of the expandable bell openinghelmet; and

a second set of hinge assembly components which are configured to bemounted to a second shell component of the expandable bell openinghelmet, wherein the first set of hinge components is configured toengage with the second set of hinge components thereby to define a hingethat rotates about a hinge axis;

wherein:

the first shell is movable with respect to the second shell thereby todefine an open and closed configuration for the helmet; and

the first and second sets of hinge assembly components are mounted tothe respective shell components to provide a hinged connection andenable the movement of the first shell with respect to the second shellabout the hinge axis.

Other embodiments include helmets having hinge assemblies as hereindescribed.

One embodiment provides an expandable bell opening helmet having atleast one interlocking edge component formed independently of a helmetshell component to which it is fixedly mounted, the helmet movablebetween: (i) a closed configuration in which the at least oneinterlocking edge member is engaged with a complementary opposinginterlocking edge; and (ii) an open configuration.

One embodiment provides a composite helmet formed from two shells,wherein the shells engage along respective interlocking edges.

One embodiment provides a composite helmet wherein at least one of theshells provides its respective interlocking edge by way of mounting ofan interlocking edge component to the shell.

Reference throughout this specification to “one embodiment”, “someembodiments” or “an embodiment” means that a particular feature,structure or characteristic described in connection with the embodimentis included in at least one embodiment of the present invention. Thus,appearances of the phrases “in one embodiment”, “in some embodiments” or“in an embodiment” in various places throughout this specification arenot necessarily all referring to the same embodiment, but may.Furthermore, the particular features, structures or characteristics maybe combined in any suitable manner, as would be apparent to one ofordinary skill in the art from this disclosure, in one or moreembodiments.

As used herein, unless otherwise specified the use of the ordinaladjectives “first”, “second”, “third”, etc., to describe a commonobject, merely indicate that different instances of like objects arebeing referred to, and are not intended to imply that the objects sodescribed must be in a given sequence, either temporally, spatially, inranking, or in any other manner.

In the claims below and the description herein, any one of the termscomprising, comprised of or which comprises is an open term that meansincluding at least the elements/features that follow, but not excludingothers. Thus, the term comprising, when used in the claims, should notbe interpreted as being limitative to the means or elements or stepslisted thereafter. For example, the scope of the expression a devicecomprising A and B should not be limited to devices consisting only ofelements A and B. Any one of the terms including or which includes orthat includes as used herein is also an open term that also meansincluding at least the elements/features that follow the term, but notexcluding others. Thus, including is synonymous with and meanscomprising.

As used herein, the term “exemplary” is used in the sense of providingexamples, as opposed to indicating quality. That is, an “exemplaryembodiment” is an embodiment provided as an example, as opposed tonecessarily being an embodiment of exemplary quality.

The disclosures of PCT Publications WO 2012/058712 and WO 2007/059575are incorporated by cross reference in their entireties.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described, by way of exampleonly, with reference to the accompanying drawings in which:

FIG. 1 provides a side view of a helmet according to one embodiment.

FIG. 2A to FIG. 2D schematically illustrate a manufacturing process foran interlocking edge arrangement for a helmet such as that of FIG. 1.

FIG. 3A and FIG. 3B provide views of a helmet latch arrangementaccording to one embodiment, which is in some embodiments used for thehelmet of FIG. 1.

FIG. 4A and FIG. 4B provide further views of the helmet latcharrangement.

FIG. 5 provides a further view of the helmet latch arrangement, shown inconjunction with a secondary locator arrangement.

FIG. 6 shows the helmet of FIG. 1 with the locator arrangement of FIG.5.

FIG. 7 shows a more detailed view of a region of the FIG. 5, focussed onthe locator arrangement.

FIG. 8A to FIG. 8I illustrate operation of a helmet latch arrangementaccording to one embodiment.

FIG. 9 illustrates a helmet dorsal hinge arrangement according to oneembodiment, which is in some embodiments used for the helmet of FIG. 1.

FIG. 10 provides a further view of the helmet dorsal hinge arrangement.

FIG. 11 provides a further view of the helmet dorsal hinge arrangement.

FIG. 12 provides a further view of the helmet dorsal hinge arrangement.

FIG. 13 provides a further view of the helmet dorsal hinge arrangement,shown in cross-section with the helmet of FIG. 1.

FIG. 14 provides a further view of the helmet dorsal hinge arrangement,shown in cross section.

FIG. 15 provides a view of a further exemplary helmet dorsal hingearrangement, shown in cross section.

FIG. 16A and 16B provide a further views of the hinge arrangement ofFIG. 15.

FIG. 17A and 17B illustrate operation of the hinge arrangement of FIG.15.

FIG. 18 provides a further view of the hinge arrangement of FIG. 15.

FIG. 19A and FIG. 19B illustrate a visor connection arrangementaccording to one embodiment.

FIG. 20A and FIG. 20B illustrate a disc component of the visorconnection arrangement of FIG. 19A and FIG. 19B.

FIG. 21A to FIG. 21C provide further views of the visor connectionarrangement.

FIG. 22 illustrates the visor connection arrangement in cross-section.

DETAILED DESCRIPTION

The present invention relates to protective helmets, and methods formanufacturing protective helmets. Embodiments described herein areparticularly relevant to protective helmets having enlargeable bellopenings, for example rear opening helmets.

Context

As noted, embodiments described herein are particularly relevant toprotective helmets having enlargeable bell openings, for example rearopening helmets. Examples of helmets are disclosed in PCT Publication WO2012/058712 and WO 2007/059575. In overview, such helmets include two(or, in some embodiments, more) shell portions which are movablerelative to one another thereby to enlarge the helmet's bell opening(the opening into which a user's head is inserted to apply the helmet).

A significant subset of enlargeable bell opening helmets is “restrictedbell opening helmets”. Such helmets are sized such that the bell openingis circumferentially smaller than the user's lower head (for example atthe height of the chin). This prevents the helmet from being applied orremoved when shell portions collectively defining the bell opening arein a closed configuration. Those shell portions must be moved relativeto one another, into an open configuration, to permit a user to apply orremove the helmet. In this regard, the use of a restricted bell openingdesign is optionally implemented as an alternative to conventional chinstrap designs (where the bell opening is of a fixed size that permitsapplication and removal of the helmet, with a chin strap used to preventpremature or other unwanted removals of the helmet).

It should be appreciated that, where the present disclosure deals withrelative sizes of a user's head and a helmet, it is to be interpretedthat the helmet has an intended head size range, and the user inquestion has a head size falling within that range. That is, thedisclosure herein describes example helmets that are sized for a rangeof user head sizes into which example user's heads described hereinfall. Accordingly, where a “helmet is sized such that the bell openingis circumferentially smaller than the user's lower head”, that refers toa user having a head size in a range for which the helmet isspecifically configured.

In some examples considered below, restricted bell opening helmets aredefined by cutting a full helmet shell into two portions, for example afront and rear portion. This results in splitting of an edge thatdefines the bell opening, such that enlarging the bell opening includesmoving the bell opening portions of the front and rear shell relative toone another. The cut line that separates the shells is defined suchthat, when in the open configuration, the bell opening can be consideredas either: (i) an opening defined by the closed-configuration bellopening edges and space defined there between; or (ii) an openingdefined by the closed-configuration bell opening edges and edges ofopposed shell edges that abut/interconnect when the helmet is in theclosed configuration. The cut line between the shell potions is definedsuch that, for a helmet designed for a head in a size range X-Y, a headin the size X-Y:

Is not able to be inserted into the helmet in a closed configuration;Is not able to be removed from the helmet in the closed configuration(due to bell opening sizing relative to head dimensions at approximatelychin level); andIs able to be progressed into the front shell in a generally forwardmanner when the head is open due to an adequate opening being defined bythe front shell edge along which interlocking occurs.

The examples disclosed in PCT Publications WO 2012/058712 and WO2007/059575 show a form of enlargeable bell opening helmets: rearopening helmets. These include a front shell and a rear shell, with therear shell being movable with respect to the front shell to enlarge thebell opening (and hence permit helmet application and removal). Moreparticularly, the helmets of those publications make use of a dorsalhinge connection, which permits relative rotation of the front and rearshells. Side fasteners (for example latch arrangements) enable thelocking of the helmet in the closed configuration.

Various embodiments are described below by reference to a rear-openinghelmet similar to that of PCT Publications WO 2012/058712 and WO2007/059575, in the sense of there being utilisation of a dorsal hingeand side fasteners. However, it should be appreciated that the variousaspects of technologies described (for example by reference to helmetmanufacturing methods, latch arrangements and visor arrangements) are byno means limited to that specific form of enlargeable bell openinghelmet, and are applicable to a wide range of other forms of enlargeablebell opening helmets, and in some cases to protective helmets moregenerally.

By way of example, other possible configurations include:

Hinges other than dorsal hinges—for example side hinges.Arrangements in which two shell components collectively defining thebell opening are configured to be slidable relative to one-another. Forexample, the rear shell, or a rear shell region, is rearwardly slidablealong a defined track to define the open configuration.Arrangements in which two shell components collectively defining thebell opening are detachable and re-attachable to respectively open andclose the helmet. In some cases upon detachment, a secondary connectionarrangement (for example a resiliently biased tether, such as an elasticconnection) biases the detached shells towards the closed configuration.Any helmet where a rear portion partially defining a bell opening ismovable thereby to enable insertion of a head into a restricted bellopening helmet.Any helmet where a shell portion containing chin cup component (forexample an adjustable and/or resiliently biased chin cup component asdisclosed in 2007/059575) is movable thereby to enable insertion of ahead into a restricted bell opening helmet.

Various other configurations are also possible.

Exemplary Helmet

FIG. 100 illustrates a helmet 100 according to one embodiment. Variousaspects of helmet technology, which also form embodiments of inventionsdisclosed herein, are illustrated in conjunction with the helmet of FIG.1.

Helmet 100 is defined by a front shell 101 and a rear shell 102, whichare separated along a separation line 103. The helmet is illustrated inside view, with a visor 105 at the front, and a restricted bell openingat the bottom. As discussed above, due to the restricted bell opening,the helmet is sized such that a wearer can only apply or remove thehelmet when it is in an open configuration (where the bell opening isenlarged due to relative movement of shells 101 and 102).

The shells include respective interlocking edge regions. In particular,at least a portion of the edge of each shell at the separation lineincludes male or female regions, which interlockingly engage withcomplementary female or male regions on the opposing shell edge uponclosure. Various interlocking edge designs and configurations are usedin embodiments, and a range of examples are illustrated in WO2007/059575. In the illustrated, the interlocking edges are presentalong side regions of the helmet. More particularly, on each side of thehelmet they extend substantially from the hinge assembly to a latchassembly (which is in FIG. 1 concealed by latch assembly covers 110 and111).

In this embodiment, interlocking edge components 108 and 109 areillustrated. These components are formed from plastics materials(preferably with resilient properties), and connected to the helmetshells during a manufacture process discussed further below. However, insome embodiments either or both of the interlocking edge components maybe integrally formed with the helmet shell.

In the illustrated embodiment, both the front and rear shells areconstructed from composite materials (for example carbon fibre), using aconstruction technique discussed further below by which the shells areinitially defined by a single helmet, which is subsequently cut todefine the two separate shells. However, in other embodiments alternatematerials are used, and alternate construction techniques used. Forinstance, in some embodiments either or both shells are formed from ABS(Acrylonitrile Butadiene Styrene).

Shell 101 is hingedly connected to shell 102 by a dorsal hinge assemblyat region 104 (described in more detail further below). This allowsshells 101 and 102 to rotate relative to one another about the axis ofthe hinge of the hinge assembly, generally along a path illustrated byarrow 106.

Upon closure of the helmet, interlocking edge components 108 and 109complementarily engage, and the latch assembly (concealed by covers 110and 111) on each side of the helmet automatically locks the helmetshells securely together (by way of a spring-loaded arrangement) asdiscussed further below. To re-open the helmet, a user manipulatesbuttons 112 provided for each of the side latch assemblies thereby torelease the latch assemblies, and allow outward relative rotation of theshells.

An adjustable chin cup component is provided within the helmet at region120. This is adjusted based on a particular user's size, thereby to cupthe wearer's chin when the helmet is worn, and allow limited someresiliently restrained motion of the chin relative to the hard shell atregion 120. The chin cup is not to be confused with a chin strap; a chincup is a component that is configured to content a wearer's chin regionat locations at each side or, and preferably both above and below, achin-point extremity of the wearer's chin. A chin strap, on the otherhand, is a component that is configured to be located below a wearer'schin.

Manufacturing Method Enabling Separable Interlocking Edge Components

FIG. 2A to FIG. 2D schematically illustrate a manufacturing process foran interlocking edge arrangement for a helmet such as helmet 100 of FIG.1.

Known two-part helmet configurations make use of interlocking edges thatare integrally formed from the helmet shells. This typicallynecessitates initial construction of two individual shells, which can beproblematic due to issues such as inconsistent shrinkage of the shells.It also creates challenges in using a full composite helmet, as thecomposite materials are not suitable for formation of integralinterlocking edges (which may favour using a helmet that has a compositefront shell and an ABS rear shell).

Embodiments of the present technology include helmets and manufacturingtechniques that make use of interlocking edge components which aremanufactured independently of helmet shells, and mounted to helmetshells during the manufacture process. Some embodiments include amanufacturing process that includes:

Forming a primary helmet shell, the helmet shell having a bell openingdefined by a bell opening edge;Applying a cutting process to the primary helmet shell thereby to definea first shell component and a second shell component, such each of thefirst and second shell components include respective regions of the bellopening edge;For at least one of the first and second shell components, mounting atleast one interlocking edge member to an edge of the shell component,being an edge defined by the cutting process; andConstructing a helmet including the at least one of the first and secondshell components to which the at least one interlocking edge member ismounted, wherein the constructed helmet is movable between: (i) a closedconfiguration in which the at least one interlocking edge member isengaged with a complementary opposing interlocking edge; and (ii) anopen configuration.

Preferably the method includes, for each of the for at least one of thefirst and second shell components, mounting at least one interlockingedge member to an edge of the shell component, being an edge defined bythe cutting process. This then involves constructing a helmet includingthe first and second shell components, wherein the constructed helmet ismovable between: (i) a closed configuration in which the respective atleast one interlocking edge members of the first and second shellcomponents are complementarily engaged; and (ii) an open configuration.

There are various design options available for interlocking edgeconfigurations. For example, an one interlocking edge member may bemounted to either or both shells, and on either shell there may be asingle interlocking edge member or multiple interlocking edge members(for example with the multiple members defining a segmented interlockingedge).

In a preferred embodiment, the method includes, for each of the firstand second shell components, mounting a pair of interlocking edge memberto an edge of the shell component. This is the case in FIG. 1, where apair of interlocking edge members 108 are mounted to shell component 101(extending substantially from the hinge assembly to a latch assembly),and a pair of interlocking edge members 109 are mounted to shellcomponent 101 (extending substantially from the hinge assembly to alatch assembly). That is, there is a member 108 on each side of thehelmet, and a member 109 on each side of the helmet.

FIG. 2A illustrates, in cross section, a region of a composite helmetshell that is initially formed. This includes a recessed region 201,which extends along a circumference of the shell. The width and depth ofthe recessed region varies along its length, depending on componentsthat are to be mounted. For example, FIG. 13 shows a portion of arecessed region which is sized and shaped to enable concealed mountingof a hinge assembly.

The cutting process is applied to helmet shell 200, thereby to definehelmet shell components 210 and 211 (which may correspond to shellcomponents 101 and 102 of FIG. 1). Here, the cutting process includesremoving one or more shell regions defined between an edge of the firstshell defined by the current process and an edge of the second shelldefined by the cutting process. One of these is shown as region 212.These regions are have a width dimension substantially corresponding toa width dimension between the first and second shell components when thehelmet is in the closed configuration, as best shown in FIG. 2D. Inessence, the removed regions account for the inter-shell pace occupiedby the interlocking edge components.

As shown in FIG. 2C, interlocking edge components 220 and 221 aremounted to edges of shell components 201 and 211 (being edges definedduring the cutting process). The interlocking edge components areelongate, and mounted to extend along those helmet shell edges for aportion (preferably a substantial portion) of the edges that is notoccupied by hinge components, latch components, and so on.

Interlocking edge components 102 and 211 are preferably formed ofplastics (for example via an injection moulding process, 3D printingprocess, or the like), and are in some embodiments formed of a plasticsmaterial having resilient properties thereby to allow limited resilientmovement between the shells of the closed helmet.

At least one of the interlocking edge members includes a male region 222that interlocks with a complementary female region 223 of the otherinterlocking edge member. In some embodiments one interlocking edgemember is wholly male and the other female, but in other embodimentsthey each include both male and female regions. It will be appreciatedthat a wide range of interlocking edge designs may be achieved usingconstruction techniques such as injection moulding and/or 3D printing.FIG. 2D shows mutual engagement of the male and female portions, whichoccurs upon closure of a fully constructed helmet.

The interlocking edge members are in the illustrated embodiment sandwichmounted around each helmet shell along an edge defined by recessedregion 201. This may be achieved by way any one or more of: adhesives,heat, mounting members (such as rivets or screws) and so on. In somecases apertures are formed through a shell adjacent the edge to assistin such mounting.

Exemplary Latch Arrangement

FIG. 3A to FIG. 7 illustrate an exemplary latch arrangement for thehelmet of FIG. 1. In overview, some embodiments include latch assemblyfor an expandable bell opening helmet, such as the helmet of FIG. 1(which includes two such latch assemblies; one on each side).

Referring to FIG. 4A, a latch assembly 400 a first set of latch assemblycomponents 401 which are configured to be mounted to shell component101, and a second set of latch assembly components 402 which areconfigured to be mounted to a second shell component of the expandablebell opening helmet.

The first set of latch assembly components 401 includes a trappablemember receiving region 410 (partially concealed in FIG. 4A). Thetrappable member receiving region includes tapered edges configured toguide a trappable member 411 (provided on a first plate member 412,mounted to the helmet shell by mounting components 421) into thetrappable member receiving region. That is, upon closure of the helmet,those tapered edges assist in progressively guiding the trappable memberinto the trappable member receiving region to a point where it isconfigured to be trapped. The trapping is effected by way of a springloaded capture mechanism, the spring loaded capture mechanism being isconfigured to prevent removal of the trappable member in the trappablemember receiving region under influence of spring loading.

The spring loaded capture mechanism is configured to move against thedirection of spring loading upon engagement with the trappable member asthat trappable member is progressed towards the trappable memberreceiving region, thereby enabling automated insertion and capture ofthe trappable member in the trappable member receiving region. In thisembodiment, such a functionality is achieved by way of a sloped edge414.

The trappable member receiving region is defined by a second platemember 415 that is configured to be mounted to the first helmet shellcomponent (see mounting components 420 of FIG. 4B). The spring loadedcapture mechanism is rotationally mounted to the second plate member byan axel mount 422.

The spring loaded capture mechanism includes a button component 425which is configured to be manually manipulated thereby to enablemovement of the spring loaded capture mechanism against the direction ofspring loading, and hence enable removal of the trappable member fromthe trappable member receiving region.

Upon engagement, the first plate member 412 and the second plate member415 correctively sandwich a guide plate member 425 of the spring loadedcapture mechanism.

The trappable member includes a region of first radius that extends fromfirst plate 412, which is captured in the trappable member receivingregion 410, and a region of second radius which extends from the regionof first radius, wherein the region of second radius and the guide platecollectively sandwich second plate member 415.

FIG. 8A to FIG. 8I illustrate operation of a latch arrangement havingcorresponding characteristics to that described above. Correspondingreference numbers are used in FIG. 8A to FIG. 4A and FIG. 4B. HoweverFIG. 8A is shown without a component corresponding to button 425 for thesake of clarity, although it will be appreciated how such a button isable to be mounted at or proximal region 430.

FIG. 8A illustrates the direction of rotation of the spring loadedcapture mechanism for the purpose of unlocking/opening. As shown in FIG.8B, this rotation brings the guide plate away from the trappable memberreceiving region, thereby allowing removal of the trappable member asshown in FIG. 8C. The spring loaded capture mechanism then returns toits spring loaded bias position as shown in FIG. 8D and FIG. 8E.

FIG. 8F illustrates the direction of approach of the trappable memberupon closure of the helmet (by relative rotation of the shells). Thispushes against sloped surface 414, thereby to act against the springbias, and allow capture of the trappable member in the trappable memberreceiving region upon return of the spring loaded capture component (seeFIG. 8H).

FIG. 8I provides a rear perspective view showing an optional locationfor a spring component 460 which provides spring loading for the springloaded capture component.

Referring to FIG. 5, in some embodiments (such as that of FIG. 1), latchassembly 400 includes a non-locking latch component 470. In overview,this is mounted at a location spaced apart from locking components 401and 402, for example as shown in FIG. 6 and FIG. 7. The lockingcomponents are configured primarily to provide locking functionality.The non-locking components are configured to provide robust inter-shelllocating for helmet structural integrity upon closure. Latch component470 includes a non-locking capture mechanism 472, including a prong 474,and a second non-locking capture mechanism 471; which is configured toengage with non-locking capture mechanism 472, including a prongcapturing loop 473. The prong preferably has a tapered leading end, toassist in accurate insertion into the prong capturing loop.

In use, non-locking latch assembly components 471 and 472 engage uponclosure of the helmet thereby to restrict relative movement of thehelmet shell components along at least a first axis and a second axis,the first axis being substantially parallel to a shell edge and thesecond axis being substantially normal to a shell surface.

Exemplary Dorsal Hinge Assembly

FIG. 9 illustrates dorsal hinge assembly 900 according to one embodimentfor the helmet of FIG. 1. Further views are shown in FIG. 10 to FIG. 14.Notably, FIG. 13 provides a cross-section of the dorsal hingearrangement mounted to the helmet of FIG. 1.

Assembly 900 includes a first set of hinge assembly components 901 whichare configured to be mounted to a shell component 101. Morespecifically, components 901 include an injection moulded hinge half910. This includes formations 912 that are configured to receivethreaded screws for securing to hinge half 910 the helmet shell.Apertures 913 provides access to selectively insert or remove screws,which as discussed below enables detachment of hinge half 910 thereby toallow a safety release function, as discussed further below.

A second set of hinge assembly components 902 which are configured to bemounted to shell component 102. These include an injection moulded hingehalf 920, which is secured through the shell component using mountingformations 921. These are not externally accessible, and hinge half 920is not intended to be removed as part of intended helmet operation.

Hinge half 901 is configured to engage with hinge half 920 thereby todefine a hinge that rotates about a hinge axis defined by a hinge pin930. The relative positioning of axial apertures defined through hingehalves 910 and 920 allows a substantially smooth top surface transitionbetween the hinge halves. As shown in FIG. 13, this is mounted in arecess such that the hinge assembly sits substantially flush with thehelmet surface, adopting a similar overall curved configuration.

Hinge halves 910 and 920 each include a plurality of parallel ribs, witha hinge pin receiving aperture being formed axially through those ribs.The ribs inter-engage in a multi-layer sandwich configuration when thehinge assembly is formed, which is beneficial in terms of providingrigidity to the hinge. Furthermore, the ribs are shaped such that upondetachment of hinge half 910 from shell component 101, hinge half 910 isable to be laterally separated from the hinge pin, thus enablingseparation of the shell components from one another without removing thehinge pin from hinge half 920.

FIG. 16A to FIG. 18 provide views of an alternate hinge assembly havingsimilar features. Corresponding reference numerals are provided in FIG.16A for guidance. FIG. 16A additionally illustrates an elastomer spring980 configured to resiliently bias the hinge assembly out of a definedclosed helmet hinge assembly position. This means that: (i) additionalforce is required to close the helmet, reducing the likelihood ofaccidental closure; and (ii) upon manipulating the latch releasebuttons, the helmet automatically springs open.

Conclusions and Interpretation

It should be appreciated that in the above description of exemplaryembodiments of the invention, various features of the invention aresometimes grouped together in a single embodiment, FIG., or descriptionthereof for the purpose of streamlining the disclosure and aiding in theunderstanding of one or more of the various inventive aspects. Thismethod of disclosure, however, is not to be interpreted as reflecting anintention that the claimed invention requires more features than areexpressly recited in each claim. Rather, as the following claimsreflect, inventive aspects lie in less than all features of a singleforegoing disclosed embodiment. Thus, the claims following the DetailedDescription are hereby expressly incorporated into this DetailedDescription, with each claim standing on its own as a separateembodiment of this invention.

Furthermore, while some embodiments described herein include some butnot other features included in other embodiments, combinations offeatures of different embodiments are meant to be within the scope ofthe invention, and form different embodiments, as would be understood bythose skilled in the art. For example, in the following claims, any ofthe claimed embodiments can be used in any combination.

In the description provided herein, numerous specific details are setforth. However, it is understood that embodiments of the invention maybe practiced without these specific details. In other instances,well-known methods, structures and techniques have not been shown indetail in order not to obscure an understanding of this description.

Thus, while there has been described what are believed to be thepreferred embodiments of the invention, those skilled in the art willrecognize that other and further modifications may be made theretowithout departing from the spirit of the invention, and it is intendedto claim all such changes and modifications as falling within the scopeof the invention. For example, any formulas given above are merelyrepresentative of procedures that may be used. Functionality may beadded or deleted from the block diagrams and operations may beinterchanged among functional blocks. Steps may be added or deleted tomethods described within the scope of the present invention.

1. (canceled)
 2. (canceled)
 3. (canceled)
 4. (canceled)
 5. (canceled) 6.(canceled)
 7. (canceled)
 8. (canceled)
 9. (canceled)
 10. (canceled) 11.A method of manufacturing a helmet, the method including: forming aprimary helmet shell, the helmet shell having a bell opening defined bya bell opening edge; applying a cutting process to the primary helmetshell thereby to define a first shell component and a second shellcomponent; for at least one of the first and second shell components,mounting at least one interlocking edge member to an edge of the shellcomponent, being an edge defined by the cutting process; andconstructing a helmet including the at least one of the first and secondshell components to which the at least one interlocking edge member ismounted.
 12. A method according to claim 11 including: for each of thefor at least one of the first and second shell components, mounting atleast one interlocking edge member to an edge of the shell component,being an edge defined by the cutting process; and constructing a helmetincluding the first and second shell components.
 13. A method accordingto claim 12 including: for each of the for at least one of the first andsecond shell components, mounting a pair of interlocking edge member toan edge of the shell component, being an edge defined by the cuttingprocess.
 14. (canceled)
 15. A method according to claim 12 wherein thecutting process includes removing one or more shell regions definedbetween an edge of the first shell defined by the current process and anedge of the second shell defined by the cutting process.
 16. A methodaccording to claim 15 wherein at least one of the removed shell regionshas a width dimension substantially corresponding to a width dimensionbetween the first and second shell components when the helmet is in theclosed configuration.
 17. A method according to claim 12 wherein the atleast one interlocking edge member mounted to the first shell componentincludes a male region that interlocks with a complementary femaleregion of the at least one interlocking edge member mounted to thesecond shell component when the helmet is in the closed configuration.18. A method according to claim 12 wherein the helmet includes a hingeassembly that is configured to enable relative rotation of the firstshell component relative to the second shell component, thereby toenable enlargement of the bell opening.
 19. A method according toclaimer 18 wherein the helmet includes at least one latch assembly thatenable securing of the helmet in the closed configuration.
 20. A methodaccording to claimer 19 wherein the at least one interlocking edgemember is mounted to the first shell component along an edge regiondefined by the cutting process intermediate the hinge assembly and theat least one latch assembly.
 21. A method according to claim 11 whereinthe at least one interlocking edge component is formed of resilientmaterial.
 22. A helmet formed by a method according to claim
 11. 23. Anexpandable bell opening helmet having at least one interlocking edgecomponent formed independently of a helmet shell component to which itis fixedly mounted, the helmet movable between: (i) a closedconfiguration in which the at least one interlocking edge member isengaged with a complementary opposing interlocking edge; and (ii) anopen configuration.
 24. (canceled)
 25. (canceled)
 26. A latch assemblyfor an expandable bell opening helmet, the latch assembly including: afirst set of latch assembly components which are configured to bemounted to a first shell component of the expandable bell openinghelmet; and a second set of latch assembly components which areconfigured to be mounted to a second shell component of the expandablebell opening helmet; wherein: the first shell is movable with respect tothe second shell thereby to define an open and closed configuration forthe helmet, wherein: in the open configuration the bell opening isexpanded; and in the closed configuration the first set of latchassembly components interface with the second set of latch assemblycomponents thereby to lock the helmet in the closed configuration; andthe first set of latch assembly components includes: (i) a trappablemember receiving region, wherein the trappable member receiving regionincludes tapered edges configured to guide a trappable member into thetrappable member receiving region; and (ii) a biased capture mechanism,wherein the biased capture mechanism is configured to prevent removal ofthe trappable member in the trappable member receiving region underinfluence of spring loading; the second set of latch assembly componentsincludes a first plate member that provides the trappable member. 27.(canceled)
 28. (canceled)
 29. (canceled)
 30. (canceled)
 31. (canceled)32. (canceled)
 33. (canceled)
 34. (canceled)
 35. (canceled) 36.(canceled)
 37. A helmet including a latch assembly according to claim26.
 38. A hinge assembly for an expandable bell opening helmet, thehinge assembly including: a first set of hinge assembly components whichare configured to be mounted to a first shell component of theexpandable bell opening helmet; and a second set of hinge assemblycomponents which are configured to be mounted to a second shellcomponent of the expandable bell opening helmet, wherein the first setof hinge components is configured to engage with the second set of hingecomponents thereby to define a hinge that rotates about a hinge axis;wherein: the first shell is movable with respect to the second shellthereby to define an open and closed configuration for the helmet; andthe first and second sets of hinge assembly components are mounted tothe respective shell components to provide a hinged connection andenable the movement of the first shell with respect to the second shellabout the hinge axis.
 39. (canceled)
 40. (canceled)
 41. (canceled) 42.(canceled)
 43. A helmet including a hinge assembly according to claim38.
 44. A method according to claim 11 wherein the cutting process isapplied such that each of the first and second shell components includerespective regions of the bell opening edge; and wherein the constructedhelmet is movable between: (i) a closed configuration in which the atleast one interlocking edge member is engaged with a complementaryopposing interlocking edge; and (ii) an open configuration.
 45. A methodaccording to claim 12 wherein the constructed helmet is movable between:(i) a closed configuration in which the respective at least oneinterlocking edge members of the first and second shell components arecomplementarily engaged; and (ii) an open configuration.
 46. A methodaccording to claim 13 including constructing a helmet including thefirst and second shell components, wherein the constructed helmet ismovable between: (i) a closed configuration in which the pair ofinterlocking edge members of the first shell component arecomplementarily engaged with the pair of interlocking edge members ofthe second shell component and (ii) an open configuration.